U.S. patent application number 12/984204 was filed with the patent office on 2011-08-04 for fine composite metal particles and their production method, micro-bodies, and magnetic beads.
This patent application is currently assigned to HITACHI METALS, LTD. Invention is credited to Shigeo FUJII, Yasushi KANEKO, Hisato TOKORO.
Application Number | 20110185851 12/984204 |
Document ID | / |
Family ID | 34753502 |
Filed Date | 2011-08-04 |
United States Patent
Application |
20110185851 |
Kind Code |
A1 |
KANEKO; Yasushi ; et
al. |
August 4, 2011 |
Fine Composite Metal Particles and Their Production Method,
Micro-Bodies, and Magnetic Beads
Abstract
Fine composite metal particle comprising a metal core and a
coating layer of carbon, and being obtained by reducing metal oxide
powder with carbon powder.
Inventors: |
KANEKO; Yasushi;
(Saitama-ken, JP) ; FUJII; Shigeo; (Saitama-ken,
JP) ; TOKORO; Hisato; (Saitama-ken, JP) |
Assignee: |
HITACHI METALS, LTD
Tokyo
JP
|
Family ID: |
34753502 |
Appl. No.: |
12/984204 |
Filed: |
January 4, 2011 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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11681059 |
Mar 1, 2007 |
7892316 |
|
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12984204 |
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10934515 |
Sep 7, 2004 |
7285329 |
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11681059 |
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Current U.S.
Class: |
75/343 |
Current CPC
Class: |
B22F 2001/0029 20130101;
G11B 5/70615 20130101; B22F 2998/00 20130101; B22F 1/0059 20130101;
B22F 2998/00 20130101; G11B 5/714 20130101; B22F 9/20 20130101;
H01F 1/33 20130101; Y10T 428/265 20150115; C22C 33/0257 20130101;
H01F 1/0054 20130101; B22F 1/025 20130101; B22F 1/0062 20130101;
B22F 2998/00 20130101; B22F 2999/00 20130101; B22F 2998/00
20130101; B82Y 25/00 20130101; B22F 2201/11 20130101; B22F 2201/30
20130101; B22F 1/025 20130101; B22F 9/20 20130101; B22F 9/20
20130101; B22F 1/02 20130101; B22F 1/0018 20130101; B22F 2201/02
20130101; B22F 1/0018 20130101; B22F 1/0051 20130101; G11B 5/712
20130101; H01F 1/26 20130101; B22F 1/02 20130101; H01F 1/061
20130101; H01F 1/065 20130101; H01F 1/20 20130101; Y10T 428/12181
20150115; B22F 2999/00 20130101; Y10T 428/2991 20150115; Y10T
428/2998 20150115 |
Class at
Publication: |
75/343 |
International
Class: |
B22F 9/00 20060101
B22F009/00; B05D 7/14 20060101 B05D007/14 |
Foreign Application Data
Date |
Code |
Application Number |
Feb 18, 2004 |
JP |
2004-41659 |
Feb 24, 2004 |
JP |
2004-48480 |
Feb 27, 2004 |
JP |
2004-53554 |
Claims
1-31. (canceled)
32. A method for producing fine composite metal particles
comprising the steps of mixing oxide powder of a magnetic metal, at
least one of boron-containing powder and carbon powder, and powder
containing at least one element selected from the group consisting
of Al, As, Be, Cr, Ga, Ge, Mo, P, Sb, Si, Sn, Ti, V, W and Zn to
provide a mixed powder; heat-treating said mixed powder in a
non-oxidizing atmosphere to produce fine metal particles comprising
at least one of said elements and coated with a layer comprising
carbon and/or boron nitride.
33-35. (canceled)
36. The method for producing fine composite metal particles
according to claim 32, which comprises further coating the
resultant coated fine metal particles with a layer of an inorganic
material.
37. The method for producing fine composite metal particles
according to claim 36, wherein the layer of said inorganic material
is substantially composed of silicon oxide composed of silicon
oxide formed by hydrolyzing silicon alkoxide.
38. The method for producing fine composite metal particles
according to claim 37, wherein said layer of silicon oxide is
formed from silicon alkoxide, water, catalyst and an electrolyte in
an alcohol solvent.
39. The method for producing fine composite metal particles
according to claim 38, wherein after forming said silicon oxide
layer, said fine composite metal particles are further coated with
an amino-group-containing silane coupling agent to introduce an
--HN.sub.2 group.
Description
[0001] This is a divisional of application Ser. No. 11/681,059
filed Mar. 1, 2007, which is a divisional of application Ser. No.
10/934,515 filed Sep. 7, 2004, now U.S. Pat. No. 7,285,329. The
entire disclosure of the prior applications, application Ser. Nos.
11/681,059 and 10/934,515 is considered part of the disclosure of
the accompanying divisional application and is hereby incorporated
by reference.
FIELD OF THE INVENTION
[0002] The present invention relates to fine composite metal
particles and their production method, which may be used, for
instance, for magnetic recording media such as magnetic tapes,
magnetic recording disks, etc., electronic devices such as
noise-suppressing sheets, inductors, yokes, etc., magnetic beads
for extracting and separating DNA, protein components, cells,
etc.
BACKGROUND OF THE INVENTION
[0003] As electronic devices has become smaller and lighter in
weight with higher performance, materials for the electronic
devices are required to have higher properties. One of methods for
achieving such object is to make the materials as small as a
nano-size level. In magnetic products formed by compacting magnetic
powder, the use of fine magnetic powder is expected to improve soft
or hard magnetic properties.
[0004] In magnetic recording tapes having hard magnetic particles
coated on substrates, for instance, both the reduction of a
magnetic particle size and the improvement of magnetic properties
are required to increase their recording density. The magnetic
particles have conventionally been ferrite powder, which suffers
from low signal intensity because of small magnetization. To obtain
sufficient output, magnetic metal particles of Fe and/or Co are
suitable. However, when the particle size of metal particles is
made smaller than 1 .mu.m or less for higher recording density, the
oxidation reaction of metal particles vigorously occurs in the air
because they are vulnerable to oxidation, resulting in the
deterioration of magnetization.
[0005] To improve the oxidation resistance of fine metal particles
containing Fe and/or Co, proposals were made to coat the fine
magnetic metal particles with ferrite layers (for instance, JP
2000-30920 A), or to coat Fe powder with graphite (for instance, JP
9-143502 A). However, the metal oxide coating disclosed in JP
2000-30920 A is disadvantageous in considerably oxidizing the metal
particles. The coating of metal particles with graphite as
disclosed in JP 9-143502 A needs a heat treatment at as high a
temperature as 1600.degree. C. to 2800.degree. C. to melt carbon,
disadvantageous for industrial use.
[0006] When magnetic metal powder is used in the form of moldings
particularly in high-frequency applications, electrical insulation
should be secured between magnetic metal particles to improve
properties. For this purpose, each metal particle should be coated
with a high-resistance material.
[0007] Proposed as a method for solving these problems is to coat
metal particles with high-resistance boron nitride (BN) (see
International Journal of Inorganic Materials 3 2001, p. 597, 2001).
BN is a material usable for crucibles, having a melting point of
3000.degree. C. excellent in high-temperature stability, low
reactivity to metals and good insulation. The coating of metal
particles with BN can be carried out by (1) heating a mixed powder
of a metal and B by arc discharge in a nitrogen atmosphere, (2)
heating a mixed powder of a metal and B in a mixed atmosphere of
hydrogen and ammonia, or (3) heat-treating a mixture of a metal
nitrate, urea and boric acid in a hydrogen atmosphere.
[0008] However, the above methods (1)-(3) suffer from the following
disadvantages. Specifically, the above methods (1) and (2) suffer
from the risk of burning due to rapid oxidation when handling
ultrafine metal particles of 1 .mu.m or less. The method (1)
suffers from low productivity because of arc discharge, and is
disadvantageous for industrial use because of high reaction
temperatures near 2000.degree. C. The production method (3) is
likely to generate a harmful gas (NO.sub.x) because of the thermal
decomposition of metal nitrates. In addition, the hydrogen gas used
in the methods (2) and (3) is easily exploded, unsuitable for
industrial use. These methods (2) and (3) suffer from extremely low
productivity.
[0009] In addition, conventional coated metal particles have
deteriorated saturation magnetization because part of metal
particles are modified with coating materials. Thus, it is
difficult to use fine particles produced by the conventional
technologies for biochemical applications such as the extraction of
DNA and proteins, magnetic recording media, etc.
[0010] Recently, fine magnetic particles have become used in
medical diagnosis and biological examination. For instance, the use
of superparamagnetic metal oxide particles as carriers for binding
nucleic acids is proposed (JP 2001-78761 A). The superparamagnetic
metal oxide exhibits magnetization only when an external magnetic
field is applied. Because magnetic particles are exposed to acidic
or alkaline solutions in the above applications, their surfaces
should be chemically stable. In addition, antibodies for binding
target substances should be easily attached to their surfaces. When
magnetic powder is used as carriers for extracting nucleic acids,
the metal or metal oxide powder is coated with silicon oxide (JP
2000-256388 A). According to this method, only coatings or fine
particles of silicon oxide are used to cover the metal or metal
oxide powder. Silicon oxide is formed by the hydrolysis of silicon
alkoxides or by using condensed sodium silicate.
[0011] The magnetic particles for magnetic beads should have as
small a particle size as predominantly 1 to 10 nm to exhibit
superparamagnetism.
[0012] Accordingly, an extremely small force is induced in magnetic
particles by an external magnetic field, failing to gather the
particles efficiently. Because of a weak attraction force by a
magnetic field, once gathered magnetic particles are likely to flow
out together with a discharged solution. In the step of extracting
nucleic acids with magnetic powder having a silicon oxide coating
or fine silicon oxide particles on a magnetic metal core, the metal
is likely to be dissolved in a solvent or oxidized, resulting in
the deterioration of magnetic properties. The metal dissolved in a
solvent forms a complex with a buffer solution, hindering the
extraction of DNA. When the core is made of a metal oxide, the
magnetic powder has extremely lower magnetic properties than when
the core is made of a magnetic metal, resulting in lower efficiency
in the extraction of nucleic acids.
OBJECT OF THE INVENTION
[0013] Accordingly, an object of the present invention is to
provide fine composite metal particles with high saturation
magnetization and chemical stability and excellent in other
properties, and a method for producing such fine composite metal
particles.
SUMMARY OF THE INVENTION
[0014] The fine composite metal particles according to one
embodiment of the present invention have an average particle size
of 1 .mu.m or less, each fine composite metal particle comprising a
metal core and a carbon coating layer, and being obtained by
reducing metal oxide powder with carbon powder.
[0015] Each of the fine composite metal particles according to
another embodiment of the present invention comprises a metal core,
a carbon layer covering the metal core, and wire-shaped or tubular
carbon micro-bodies, which are formed by reducing metal oxide
powder in a non-oxidizing atmosphere.
[0016] The fine composite metal particles according to a further
embodiment of the present invention have an average particle size
of 1 .mu.m or less, each fine composite metal particle comprising
(a) an iron-based metal core comprising 1% or more and less than
50% by mass of at least one element selected from the group
consisting of Al, As, Be, Cr, Ga, Ge, Mo, P, Sb, Si, Sn, Ti, V, W
and Zn, and having a main structural phase of .alpha.-Fe, and (b) a
coating layer mainly composed of carbon and/or boron nitride, the
fine composite metal particles being obtained by reducing iron
oxide powder.
[0017] Each of the nano-sized, spherical, composite metal particles
according to a still further embodiment of the present invention
comprises an iron-based metal core comprising Co and/or Ni, and a
coating layer having a thickness of 1 to 40 nm, the mass ratios of
Co/Fe and Ni/Fe being 0.3 to 0.82, and 0.01 to 0.5,
respectively.
[0018] Each of the nano-sized, spherical, composite metal particles
according to a still further embodiment of the present invention
comprises an iron-based metal core comprising Co and/or Ni, and a
coating layer having a thickness of 1 to 40 nm, a ratio of the
intensity I (111) of a (111) peak of .gamma.-Fe having a
face-centered cubic crystal structure to the intensity I (110) of a
(110) peak of .alpha.-Fe having a body-centered cubic crystal
structure is 0.2 or less in an X-ray diffraction pattern.
[0019] Each of the fine composite metal particles according to a
still further embodiment of the present invention comprises a metal
core comprising a magnetic metal as a main component and having an
average particle size of 10 .mu.m or less, and a multilayer coating
of 2 or more different inorganic materials.
[0020] In the above fine composite metal particles, carbon on a
surface of each metal core is preferably composed mainly of
graphite with 2 or more crystal lattice planes. Carbon on a surface
of each metal core preferably has a thickness of 100 nm or
less.
[0021] The metal core is preferably composed mainly of a magnetic
metal; and the saturation magnetization of the fine composite metal
particles is preferably 10% or more of that of the magnetic
metal.
[0022] Increase in an oxygen content (% by mass) by a heat
treatment at a humidity of 100%, a temperature of 120.degree. C.
and 1 atm for 24 hours is preferably 50% or less relative to before
the heat treatment.
[0023] A ratio of the intensity I (111) of a (111) peak of
.gamma.-Fe having a face-centered cubic crystal structure to the
intensity I (110) of a (110) peak of .alpha.-Fe having a
body-centered cubic crystal structure is preferably 0.3 or less in
an X-ray diffraction pattern.
[0024] An innermost inorganic layer partially or entirely covering
the metal core is preferably mainly formed by carbon and/or boron
nitride. The inorganic material preferably has 2 or more crystal
lattice planes. The innermost inorganic layer preferably has a
thickness of 100 nm or less.
[0025] The innermost inorganic layer preferably comprises at least
one element selected from the group consisting of Si, V, Ti, Al,
Nb, Zr and Cr.
[0026] The inorganic layer outside the innermost inorganic layer is
preferably substantially composed of silicon oxide or gold. The
silicon oxide layer preferably has a thickness of 400 nm or less.
The outside inorganic layer is preferably coated with a resin. The
resin is preferably coated with a silicon oxide layer. The resin
layer is preferably sandwiched by the innermost inorganic layer and
the outside inorganic layer. The outside inorganic layer preferably
has at least one functional group selected from the group
consisting of --NH.sub.2, --OH and --COOH on its surface.
[0027] The method for producing fine composite metal particles
coated with carbon according to a still further embodiment of the
present invention comprises heat-treating a mixture of metal oxide
powder and carbon powder in a non-oxidizing atmosphere.
[0028] The method for producing fine composite metal particles each
comprising a metal core, a carbon layer covering the metal core,
and wire-shaped or tubular carbon micro-bodies according to a still
further embodiment of the present invention comprises heat-treating
a mixture of metal oxide powder and carbon powder in a
non-oxidizing atmosphere to reduce the metal oxide.
[0029] The method for producing fine composite metal particles
according to a still further embodiment of the present invention
comprises the steps of mixing oxide powder of a magnetic metal with
at least one of boron-containing powder and carbon powder to
provide a mixed powder, heat-treating the mixed powder in a
non-oxidizing atmosphere to produce fine metal particles each
coated with a layer based on carbon and/or boron nitride, and
further coating the resultant coated fine metal particles with an
inorganic material.
[0030] The method for producing fine composite metal particles
according to a still further embodiment of the present invention
comprises the steps of mixing oxide powder of a magnetic metal with
powder containing at least one element selected from the group
consisting of Si, V, Ti, Al, Nb, Zr and Cr to provide a mixed
powder, heat-treating the mixed powder in a non-oxidizing
atmosphere to produce fine metal particles coated with a layer
based on at least one of the elements, and further coating the
resultant coated fine metal particles with an inorganic
material.
[0031] The method for producing fine composite metal particles
according to a still further embodiment of the present invention
comprises the steps of mixing oxide powder of a magnetic metal, at
least one of boron-containing powder and carbon powder, and powder
containing at least one element selected from the group consisting
of Al, As, Be, Cr, Ga, Ge, Mo, P, Sb, Si, Sn, Ti, V, W and Zn to
provide a mixed powder; heat-treating the mixed powder in a
non-oxidizing atmosphere to produce fine metal particles containing
at least one of the above elements and coated with a layer
comprising carbon and/or boron nitride, and further coating the
resultant coated fine metal particles with an inorganic
material.
[0032] In the production method of fine composite metal particles,
the heat treatment is conducted at a temperature of 600 to
1600.degree. C. The layer of the inorganic material is preferably
substantially composed of silicon oxide formed by hydrolyzing
silicon alkoxide. The silicon oxide layer is preferably formed from
silicon alkoxide, water, a catalyst and an electrolyte in an
alcohol solvent. After forming the inorganic layer, the fine
composite metal particles are preferably further coated with an
amino-group-containing silane coupling agent to introduce an
--NH.sub.2 group.
[0033] The wire-shaped or tubular micro-bodies of graphite-phase
carbon according to a still further embodiment of the present
invention are formed by reducing metal oxide powder in a
non-oxidizing atmosphere.
[0034] The magnetic beads for extracting biosubstances according to
a still further embodiment of the present invention comprise the
above fine composite metal particles.
BRIEF DESCRIPTION OF THE DRAWINGS
[0035] FIG. 1 is a graph showing the X-ray diffraction pattern of
the mixed powder before the heat treatment;
[0036] FIG. 2 is a graph showing the X-ray diffraction pattern of
the mixed powder after the heat treatment;
[0037] FIG. 3 is an electron photomicrograph showing the particle
of the present invention structure;
[0038] FIG. 4 is a schematic view for explaining the structure of
the particle shown in FIG. 3;
[0039] FIG. 5 is an electron photomicrograph showing the particle
of the present invention structure;
[0040] FIG. 6 is a schematic view for explaining the structure of
the particle shown in FIG. 5;
[0041] FIG. 7 is an electron photomicrograph showing the particle
of the present invention structure;
[0042] FIG. 8 is a schematic view for explaining the structure of
the particle shown in FIG. 7;
[0043] FIG. 9 is a graph showing the X-ray diffraction pattern of
the mixed powder before the heat treatment;
[0044] FIG. 10 is a graph showing the X-ray diffraction pattern of
the mixed powder after the heat treatment;
[0045] FIG. 11 is an electron photomicrograph showing the particle
of the present invention structure;
[0046] FIG. 12 is a schematic view for explaining the structure of
the particle shown in FIG. 11;
[0047] FIG. 13 is an electron photomicrograph showing the particle
of the present invention structure;
[0048] FIG. 14 is a schematic view for explaining the structure of
the particle shown in FIG. 13;
[0049] FIG. 15 is a graph showing the X-ray diffraction patterns of
the powder samples;
[0050] FIG. 16 is a graph showing the X-ray diffraction patterns of
the Fe--Co particles;
[0051] FIG. 17 is a graph showing the relation between the
thickness of a silicon oxide layer and electric resistance in the
fine composite metal particles;
[0052] FIG. 18 is a TEM photograph showing the multilayer-coated
fine composite metal particle;
[0053] FIG. 19 is a schematic view for explaining the structure of
the multilayer-coated fine composite metal particle shown in FIG.
18;
[0054] FIG. 20 is a TEM photograph showing part of the
multilayer-coated fine composite metal particle of FIG. 18 in an
enlarged manner;
[0055] FIG. 21 is a schematic view for explaining the structure of
the multilayer-coated fine composite metal particle shown in FIG.
20;
[0056] FIG. 22 is a graph showing the relation between the
concentration of immunoglobulin in a protein suspension and the
amount of immunoglobulin attached to the fine composite metal
particles;
[0057] FIG. 23 is a TEM photograph showing the multilayer-coated
fine composite metal particle;
[0058] FIG. 24 is a schematic view for explaining the structure of
the fine composite metal particle shown in FIG. 23;
[0059] FIG. 25 is a photograph of the fine composite metal
particles of the present invention in a fluorescent-labeling
method, which was taken by a fluorescent inverted microscope;
[0060] FIG. 26 is a schematic view corresponding to the photograph
of FIG. 25;
[0061] FIG. 27 is a photograph showing the results of an
electrophoresis experiment with a DNA-extracting liquid, using the
fine composite metal particles of the present invention; and
[0062] FIG. 28 is a schematic view corresponding to the photograph
of FIG. 27.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0063] Each fine composite metal particle of the present invention
comprises a metal core and a coating layer, having an average
particle size of 10 .mu.m or less. The coating layer comprises 2 or
more different inorganic materials. The above particle size range
is necessary for good soft magnetic properties. When the average
particle size exceeds 10 .mu.m, the fine composite metal particles
have low dispersibility in a solvent, resulting in precipitation in
a short period of time. The average particle size of the fine
composite metal particles is desirably in a range of 0.1 to 5 .mu.m
to have extremely high dispersibility in a solvent. Though not
particularly restrictive, the lower limit of the average particle
size is preferably 10 nm, so that Fe, Co and Ni particles may have
critical sizes for superparamagnetism.
[1] Metal Core
[0064] The metal core is preferably composed of at least one
magnetic transition metal selected from the group consisting of Fe,
Co and Ni. It may be formed by Fe, Co or Ni alone or their alloys
such as Fe--Co alloys or Fe--Ni alloys, or alloys of Fe, Co and/or
Ni containing other transition metals such as Cr, Ti, Nb, Si, Zr,
etc.
[0065] Particularly in the case of iron-based alloys, elements X
added to Fe are preferably those providing a stable a phase even at
as high temperatures as 1000.degree. C. or higher when alloyed with
Fe. The iron-based alloy preferably comprises at least one element
X selected from the group consisting of Al, As, Be, Cr, Ga, Ge, Mo,
P, Sb, Si, Sn, Ti, V, W and Zn. Because finer metal Fe particles
precipitate a paramagnetic .gamma. phase having a face-centered
cubic crystal structure, resulting in decreased magnetic
properties, the element X is preferably 1 to 50% by mass in the
fine composite metal particles having an average particle size of 1
.mu.m or less to suppress the .gamma. phase. The fine composite
metal particles containing such element may be obtained by
heat-treating a mixture of at least one of boron-containing powder
and carbon powder, oxide powder of a magnetic metal, and powder
containing at least one element selected from the group consisting
of Al, As, Be, Cr, Ga, Ge, Mo, P, Sb, Si, Sn, Ti, V, W and Zn in a
non-oxidizing atmosphere. The addition of the element X forms fine
.alpha.-Fe phase particles, resulting in an intensity ratio I
(111)/I (110) of 0.3 or less in an X-ray diffraction pattern,
wherein I (111) is the intensity of a (111) diffraction peak of
.gamma.-Fe having a face-centered cubic crystal structure, and I
(110) is the intensity of a (110) diffraction peak of .alpha.-Fe
having a body-centered cubic crystal structure. Thus, even the fine
composite metal particles having an average particle size of 1
.mu.m or less, further 100 nm or less, have high saturation
magnetization. In the fine composite metal particle comprising a
metal core having a multilayer coating of inorganic materials
according to the present invention, a small metal core contributes
to high saturation magnetization.
[0066] The fine metal particles may have Fe as a main component,
and contain Co and/or Ni. The average particle size of the fine
composite metal particles is particularly preferably in a range of
1 to 10000 nm. In this case, the thickness of the coating layer is
preferably in a range of 1 to 40 nm to have high saturation
magnetization. The amounts of Co and Ni are preferably such that
mass ratios of Co/Fe and Ni/Fe are 0.3-0.82 and 0.01-0.5,
respectively, in the nano-sized, iron-based particles. In this
binary composition, the alloying of Fe with Co elevates the
transition temperature of an .alpha. phase to a .gamma. phase, a
higher temperature phase, thereby stabilizing the .alpha. phase and
suppressing the precipitation of the .gamma.-Fe phase. When the
mass ratio of Co to Fe is less than 0.3, no addition effect of Co
is expected. On the other hand, when Co/Fe exceeds 0.82, the
saturation magnetization becomes less than 120 Am.sup.2/kg. The
addition of Co in the above preferred range suppresses the
precipitation of the .gamma. phase, resulting in a ratio I (111)/I
(110) of 0.2 or less and thus high saturation magnetization,
wherein I (111) is the intensity of a (111) diffraction peak of a
face-centered cubic crystal structure (corresponding to the .gamma.
phase), and I (110) is the intensity of a (110) diffraction peak of
a body-centered cubic crystal structure (corresponding to the a
phase) in an X-ray diffraction pattern.
[0067] The ternary Fe--Co--Ni composition has, in addition to the
above effects, excellent corrosion resistance and soft magnetic
properties, high saturation magnetization, and low
magnetostriction. When the ratio of NiFe is less than 0.01 by mass,
the fine metal particles have large magnetostriction. On the other
hand, when the ratio of NiFe is more than 0.5 by mass, the fine
metal particles have saturation magnetization of less than 100
Am.sup.2/kg.
[0068] Because the Fe-based core containing Co and/or Ni has high
saturation magnetization, the metal core preferably has a
multilayer coating of inorganic materials, so that the whole coated
particles have high saturation magnetization. The metal core with
suppressed .gamma.-Fe, on which a multilayer coating of 2 or more
different inorganic materials is formed, is preferably as small as
1 .mu.m or less in an average particle size.
[2] Innermost Inorganic Coating
[0069] In the multilayer coating of 2 or more inorganic materials
formed on the metal core, an inorganic layer (innermost layer) in
direct contact with the metal core for partial or entire covering
is preferably substantially composed of carbon and/or boron
nitride. Because carbon and boron nitride have excellent
lubrication, the coating of the metal core with carbon and/or boron
nitride improves the dispersibility of metal particles. It should
be noted that carbon as a simple substance is categorized in the
inorganic materials. Carbon has a 6-membered ring structure
peculiar to graphite, which is laminated in a laminar manner. Boron
nitride also has a ring structure, which is laminated in a laminar
manner. These inorganic materials preferably cover the entire
surface of the metal core uniformly, though they may partially
cover the metal core as long as oxidation can be prevented when
exposed to the air.
[0070] The ring plane of the inorganic material in the inorganic
layer covers the metal core in a laminar manner. This is easily
achieved by carbon having a graphite structure. In the case of
boron nitride, it has a hexagonal crystal structure to achieve the
above object. The inorganic layer with such a laminar structure
preferably has excellent chemical stability, because of few
branches such as dangling bonds, etc.
[0071] The innermost layer of carbon and/or boron nitride in
contact with the metal core preferably has a thickness of 100 nm or
less. When it has a thickness exceeding 100 nm, the saturation
magnetization decreases because of an increased non-magnetic phase.
The thickness of the innermost layer is more preferably 50 nm or
less, most preferably 40 nm or less.
[0072] The innermost inorganic layer preferably has 2 or more
crystal lattice planes laminated in a laminar manner to have
excellent corrosion resistance. In the case of a single crystal
lattice plane, the existence of defects directly leads to decrease
in corrosion resistance. The thickness of the innermost layer is
preferably 1 nm or more.
[0073] In addition to carbon and boron nitride, the innermost
inorganic layer may be formed by an oxide or a nitride of at least
one element (element M) selected from the group consisting of Al,
B, Ce, Co, Cr, Ga, Hf, In, Mn, Nb, Ti, V, Zr, Sc, Si, Y and Ta.
Typical elements needing small activation energy for oxidation are
Si, V, Ti, Al, Nb, Zr and Cr.
[0074] Thus, the innermost layer may be formed by carbides,
nitrides or oxides of these elements. Because the element M, which
is more easily oxidized than Fe, Co and Ni, has a Gibbs free energy
of forming an oxide, which meets the relation (1) described below,
it can reduce oxides containing Fe, Co and Ni.
.DELTA.G.sub.(Fe,Co,Ni)-O.gtoreq..DELTA.G.sub.M-O (1),
wherein .DELTA.G.sub.(Fe, Co,Ni)--O is a Gibbs free energy of
forming oxides of Fe, Co and Ni, and AG.sub.M-O is a Gibbs free
energy of forming an oxide of the element M.
[0075] When the iron oxide is Fe.sub.2O.sub.3, the oxides, whose
.DELTA.G.sub.M-O is smaller than .DELTA.G.sub.Fe2O3 (-740 kJ/mol),
are Al.sub.2O.sub.3, As.sub.2O.sub.5, B.sub.2O.sub.3, CeO.sub.2,
Ce.sub.2O.sub.3, Ce.sub.3O.sub.4, Cr.sub.2O.sub.3, Ga.sub.2O.sub.3,
HfO.sub.2, In.sub.2O.sub.3, Mn.sub.2O.sub.3, Mn.sub.3O.sub.4,
Nb.sub.2O.sub.5, TiO.sub.2, Ti.sub.2O.sub.3, Ti.sub.3O.sub.5,
V.sub.2O.sub.3, V.sub.2O.sub.5, V.sub.3O.sub.5, ZrO.sub.2,
Sc.sub.2O.sub.3, Y.sub.2O.sub.3, Ta.sub.2O.sub.5, rare earth
oxides, etc.
[3] Formation of Metal Core and Innermost Inorganic Layer
[0076] The metal core and the innermost coating layer are produced
by heat-treating fine oxide particles of Fe, Co, Ni, etc. together
with carbon powder or boron powder in a non-oxidizing atmosphere
such as a nitrogen gas, or a mixed gas of a nitrogen gas and an
inert gas such as argon, etc.
[0077] Detailed explanation will be made, for instance, on fine
composite metal particles having an average particle size of 1
.mu.m or less, each of which comprises a metal core coated with
carbon. The fine composite metal particles can be produced by
heat-treating a mixture of oxide powder of Fe, Co, Ni, etc. and
carbon powder in a non-oxidizing atmosphere. By this production
method, the metal oxide is reduced, and graphite-based carbon with
2 or more crystal lattice planes is formed on the metal particles.
2 or more laminar crystal lattice planes are desirable to prevent
the metal particles from being oxidized. More desirably, the carbon
layer has 4 or more crystal lattice planes. The crystal lattice
planes of carbon are preferably formed along a surface of each
metal particle.
[0078] It appears that the transition metals, particularly Fe, Co
and Ni, act as catalysts for forming the graphite layer.
Accordingly, the above method has an extremely simplified step, as
compared with conventional methods conducting the formation of fine
metal particles and the coating of the fine metal particles with
carbon by different steps, thereby preventing oxidation during the
step. This method is effective to form fine composite metal
particles, which are extremely active and thus easily oxidized.
[0079] The average particle size of the fine composite metal
particles is desirably 0.001 to 10 .mu.m, more desirably 0.001 to 1
.mu.m, most desirably 0.01 to 0.1 .mu.m. Particularly when the
average particle size is 0.1 .mu.m or less, the carbon coating
exhibits a remarkable effect of preventing oxidation, and such
effect is secured in a range of 0.01 to 0.1 .mu.m. Because the fine
magnetic metal particles suffer from little deterioration of
magnetic properties by oxidation, they exhibit sufficient
magnetization even when having multilayer coatings of inorganic
materials, optimum for magnetic beads, etc.
[0080] The carbon layer of the fine composite metal particles has a
thickness of preferably 100 nm or less, more preferably 50 nm or
less, most preferably 40 nm or less. The magnetic metal core can be
coated with a thin carbon layer, the saturation magnetization of
the fine composite metal particles can be 10% or more and less than
100% of that of the magnetic metal. The fine composite metal
particles coated with carbon have such high corrosion resistance
that increase in the oxygen content after a heat treatment at a
humidity of 100%, a temperature of 120.degree. C. and 1 atm for 24
hours is 50% by mass or less relative to before the heat treatment.
Thus, chemically stable fine composite metal particles can be
obtained.
[0081] Carbon sources are suitably artificial or natural graphite,
carbon black, etc., though they may be carbon-containing compounds
such as coal, activated carbon, cokes, polymers such as aliphatic
acids, polyvinyl alcohol, etc., B-C compounds, metal-containing
carbides. Accordingly, it should be noted that the term "carbon
powder" includes not only powder of pure carbon, but also
carbon-containing compound powder. The powder of pure carbon is
most preferable to have a high-purity carbon coating layer.
[0082] The metal oxide powder preferably has an average particle
size of 0.001 to 10 .mu.m, preferably 0.001 to 1 .mu.m,
particularly 0.01 to 0.1 .mu.m. It is difficult to produce metal
oxide powder having an average particle size of less than 0.001
.mu.m, and thus it is not practical. When the average particle size
exceeds 10 .mu.m, it is difficult to sufficiently reduce the metal
oxide powder to its center, failing to obtain uniform metal
particles. The average particle size of carbon powder is preferably
0.01 to 100 .mu.m, more preferably 0.1 to 50 .mu.m. Carbon powder
of less than 0.1 .mu.m is too expensive. When the average particle
size of carbon powder exceeds 100 .mu.m, a uniform dispersion of
the carbon powder in the mixed powder cannot be obtained, failing
to uniformly coat the metal particles with carbon.
[0083] A mixing ratio of the metal oxide powder to the carbon
powder is preferably such that the carbon powder is 25 to 95% by
mass. When the carbon powder is less than 25% by mass, a sufficient
reduction reaction does not occur because of insufficient carbon.
On the other hand, when the amount of carbon powder exceeds 95% by
mass, the volume ratio of the metal oxide powder to be reduced is
impractically small.
[0084] The mixing of the metal oxide powder and the carbon powder
may be carried out by a V-type mixer, a pulverizer such as a ball
mill, a rotational mixer, a mortar, etc. The mixed powder is
charged into a heat-resistant crucible of alumina, boron nitride,
graphite, etc. together with a transition metal oxide and
heat-treated. The heat treatment atmosphere is a non-oxidizing
atmosphere such as an inert gas, which may be a nitrogen gas, or a
mixture of a nitrogen gas and another inert gas such as argon, etc.
The heat treatment temperature is preferably 600.degree. C. to
1600.degree. C., more preferably 900.degree. C. to 1400.degree. C.
The reduction reaction does not proceed at a temperature of lower
than 600.degree. C., and it takes too long time at a temperature of
lower than 900.degree. C. When it exceeds 1400.degree. C. in an
atmosphere free from oxygen, oxide ceramics of the crucible are
likely to be decomposed to discharge oxygen, and an alumina
crucible, for instance, is likely to be damaged. When it exceeds
1600.degree. C., the crucible and adjacent facilities should be
made of heat-resistant materials, resulting in extremely high
production cost.
[0085] When the transition metal oxide and the carbon powder are
heated at 600 to 1600.degree. C. in a non-oxidizing atmosphere to
produce the fine composite metal particles coated with carbon, the
metal oxide acts as a catalyst for forming wire-shaped or tubular
carbon micro-bodies having an average diameter of 0.5 .mu.m or less
as a byproduct. The term "carbon micro-bodies" includes nanotubes,
nano-wires, nano-particles, and their aggregates. The wire-shaped
or tubular carbon micro-bodies may have a graphite phase. The
tubular carbon micro-bodies may have nodes or bridges. The metal
oxide is desirably a magnetic metal oxide, and in this case, the
resultant fine composite metal particles can magnetically be
separated from the carbon micro-bodies.
[0086] The carbon micro-bodies may be hollow or solid, having an
average diameter of desirably 0.01 to 0.5 .mu.m, more desirably
0.05 to 0.5 .mu.m, particularly 0.1 to 0.3 .mu.m. The average
diameter is determined from the outer diameters of the wire-shaped
or tubular carbon micro-bodies. When the fine particles have
noncircular cross sections, their maximum outer diameters and their
minimum outer diameters are averaged to obtain the average particle
size. When the carbon micro-body has a gradually changing diameter
in a longitudinal direction, the maximum and minimum outer
diameters in a longitudinal direction are taken to determine a
middle diameter as its outer diameter. Part of the carbon
micro-bodies largely deviating from a wire or tubular shape should
be ignored in the determination of their outer diameters. The
average diameter of the wire-shaped or tubular carbon micro-bodies
is determined by measuring the outer diameters of the carbon
micro-bodies in the number of N(N.gtoreq.50) in an electron
photomicrograph, and dividing the sum of the outer diameters by
N.
[0087] Detailed explanation will then be made on fine composite
metal particles having an innermost layer (first layer) of at least
one element Z selected from the group consisting of Si, V, Ti, Al,
Nb, Zr and Cr. A mixture of the magnetic metal oxide powder and the
element Z powder is heat-treated in a non-oxidizing atmosphere such
as Ar, He, H.sub.2, N.sub.2, CO.sub.2, NH.sub.3 or their
combination.
[0088] The fine composite metal particles comprising Fe as a main
component and further containing Co and/or Ni may be produced by
using a mixture of iron oxide and oxide powder of Co and/or Ni, or
by using a composite oxide powder of Fe and Co and/or a composite
oxide powder of Fe and Ni. The iron oxide may be Fe.sub.2O.sub.3,
Fe.sub.3O.sub.4, FeO, etc., the Co oxide may be CO.sub.2O.sub.3,
CO.sub.3O.sub.4, etc., and the Ni oxide may be NiO, etc. The
composite oxide of Fe and Co may be CoFe.sub.2O.sub.4, etc., and
the composite oxide of Fe and Ni may be NiFe.sub.2O.sub.4, etc.
[0089] The powder containing the element M includes powder of a
simple element M, and powder of carbides (M-C), borides (M-B) or
nitrides (M-N). The average particle size of the element
M-containing powder is preferably 1 to 10000 nm, more preferably 1
to 1000 nm, most preferably 10 to 100 nm for a more efficient
reduction reaction. Though B and As are called "metalloid," they
are included in the metal element here.
[0090] A mixing ratio of the oxide powder containing Fe and Co
and/or Ni to the powder containing the element M (at least one
selected from the group consisting of Al, B, Ce, Co, Cr, Ga, Hf,
In, Mn, Nb, Ti, V, Zr, Sc, Si, Y and Ta) is preferably close to a
stoichiometric ratio to reduce the oxides of Fe and Co and/or Ni.
More preferably, the powder containing the element M is more than a
stoichiometric amount. When the powder containing the element M is
insufficient, the oxides of Fe and Co and/or Ni are not
sufficiently reduced by the heat treatment, resulting in sintering
of the element M particles and thus a bulky composite metal
body.
[0091] The heat treatment may be conducted in a stationary electric
furnace having a tubular chamber; an electric furnace having a
furnace tube movable during the heat treatment, such as a rotary
kiln, etc.; an apparatus for heating powder in a fluidized state;
an apparatus for heating gravitationally falling fine particles by
high-frequency plasma, etc. In any apparatus, the oxide powder is
reduced to form the metal core and the first layer simultaneously.
An additional inorganic layer is formed on the first coating layer
to provide the multilayer-coated, fine, composite metal
particles.
[0092] The simultaneous formation of the metal core and the first
layer suppresses the oxidation of the metal core. The first coating
layer makes it possible to obtain fine composite metal particles
having extremely high corrosion resistance and oxidation resistance
even from metals having poor corrosion resistance and oxidation
resistance. While a silicon oxide-based layer is formed on the
first coating layer of each fine composite metal particle, the
metal core can be efficiency prevented from deterioration. The fine
composite metal particles coated with the silicon oxide-based layer
on the first coating layer have extremely high magnetic properties,
corrosion resistance and oxidation resistance, when used as
extraction media for nucleic acids.
[4] Inorganic Layer Outside Innermost Layer
[0093] The outermost layer of each fine composite metal particle is
preferably a silicon oxide-based layer, not only to secure electric
insulation between the particles, but also to have properties as an
extraction carrier of nucleic acids. Though other insulating
inorganic materials may be used, silicon oxide is most practical
from the aspect of mass production at a low cost. Though the
magnetic metal core is preferably coated with an inert inorganic
material resistant to oxidation, etc., the outermost surfaces of
the fine composite metal particles should be active to
biosubstances such as DNA, etc., when used as biosubstance
extraction media. From this aspect, the outermost layer is
preferably composed of silicon oxide.
[0094] The silicon oxide may be obtained, for instance, by the
hydrolysis reaction of silicon alkoxides. Specific examples of the
silicon alkoxides are tetramethoxysilane, tetraethoxysilane,
tetraisopropoxysilane, tetrabutoxysilane, methyltrimethoxysilane,
methyltriethoxysilane, aminophenyltrimethoxysilane,
aminopropyltrimethoxysilane,
N-2-aminoethyl-3-aminopropyltrimethoxysilane,
3-triethoxysilyl-N-(1,3-dimethylbutylidene) propylamine,
N-2-aminoethyl-3-aminopropyltriethoxysilane,
N-2-aminoethyl-3-aminopropylmethyldimethoxysilane,
N-phenyl-3-aminopropyltriethoxysilane,
N-phenyl-3-aminopropyltrimethoxysilane, aminopropyltriethoxysilane,
dimethyldiethoxysilane, dimethyldimethoxysilane,
tetrapropoxysilane, phenyltriethoxysilane, etc. Tetraethoxysilane
is a preferable silicon alkoxide to provide silicon oxide (silica)
by a controlled hydrolysis reaction with good reproducibility. In
addition, tetraethoxysilane provides a highly insulating coating at
a relatively low cost. The silicon alkoxide may be used alone or in
combination. For instance, aminopropyltrimethoxysilane and
tetraethoxysilane may be used to form a silicon oxide layer with
improved corrosion resistance.
[0095] In addition to silicon oxide, the outermost layer may be
made of such electrically insulating inorganic oxides as alumina,
titania, zirconia, etc. These coating layers may be formed by the
hydrolysis method of metal alkoxides.
[0096] In the case of using tetraethoxysilane, the fine composite
metal particles having the metal core coated with the first
inorganic layer are dispersed in a solution of an alcohol, for
instance, a lower alcohol such as ethanol, methanol, isopropanol,
etc. To accelerate the hydrolysis reaction of tetraethoxysilane, an
ammonia water is added as a catalyst. The ammonia water contains
water in an amount equal to or more than a theoretical amount for
100% hydrolyzing tetraethoxysilane. Specifically, water is 2 mol or
more per 1 mol of tetraethoxysilane. The amount of an alcohol
solution used is preferably 100 to 10000 parts by mass per 100
parts by mass of tetraethoxysilane.
[0097] The amount of tetraethoxysilane used is preferably 5 to 80
parts by mass, more preferably 10 to 60 parts by mass, per 100
parts by mass of the fine composite metal particles. When
tetraethoxysilane is less than 5 parts by mass, it is difficult to
uniformly coat a surface of each fine composite metal particle with
a silicon oxide layer. On the other hand, when tetraethoxysilane is
more than 80 parts by mass, fine particles composed only of silicon
oxide are formed in addition to the silicon oxide layer covering
the fine composite metal particles.
[0098] The amount of water used for the hydrolysis of
tetraethoxysilane is preferably 1 to 1000 parts by mass per 100
parts by mass of tetraethoxysilane. When it is less than 1 part by
mass, the hydrolysis of tetraethoxysilane proceeds slowly,
resulting in poor production efficiency. On the other hand, when it
exceeds 1000 parts by mass, separate spherical particles of silicon
oxide are undesirably formed.
[0099] The amount of the ammonia water used as a catalyst is
preferably 10 to 100 parts by mass per 100 parts by mass of
tetraethoxysilane, for instance, when the concentration of the
ammonia water is 28%. When it is less than 10 parts by mass, the
ammonia water fails to exhibit a catalytic function. On the other
hand, when it is more than 100 parts by mass, separate spherical
particles of silicon oxide are undesirably formed. The above
dispersion of the fine composite metal particles is slightly
alkaline with pH of about 11, because ammonia water and silicon
alkoxide are contained. Accordingly, the metal particles may be
corroded. However, the inorganic layer of each fine composite metal
particle formed simultaneously with the metal core prevents the
metal core from being corroded.
[0100] To coat the fine composite metal particles uniformly with
silicon oxide, the alkoxide solution and the fine composite metal
particles are fully mixed using a motor stirrer, a V-type mixer, a
ball mill, a dissolver, or an ultrasonic machine, etc. The mixing
should be conducted longer than necessary for the hydrolysis of
tetraethoxysilane reaction. To increase the intensity of the
coating layer, it is preferable to heat-treat the coated fine
composite metal particles.
[0101] The silicon oxide layer has an amorphous structure. The
average thickness of the silicon oxide layer is preferably
determined such that the average thickness of the multilayer
inorganic coating comprising the innermost layer and the silicon
oxide layer is 500 nm or less. To obtain a sufficient magnetic
force, the saturation magnetization of the fine composite metal
particles is preferably 10% or more of that of the magnetic metal.
When the average thickness of the multilayer inorganic coating
exceeds 500 nm, the fine composite metal particles have a decreased
saturation magnetization. More preferably, the average thickness of
the silicon oxide layer is 100 nm or less. When the fine composite
metal particles of the present invention are used as
biosubstance-extracting media, which are called "magnetic beads,"
the minimum thickness of the silicon oxide layer is 5 nm, such that
sufficient chemical properties are exhibited, for instance, its
surface potential G potential) defined from the aspect of an
electric double layer is the same as that of silicon oxide.
[0102] The thickness of the coating layer is a distance between the
surface of the metal core and the coating surface. The thickness of
the coating layer is measured, for instance, by TEM. The TEM
observation of a sample particle reveals that there is contrast
between the metal core, the innermost layer of carbon and/or boron
nitride and the silicon oxide layer, indicating that the carbon
and/or boron nitride layer and the silicon oxide layer are formed
on the metal core surface. The average thickness is determined from
10 or more of the fine composite metal particles. With respect to
each particle, the thickness of the layer is measured at 4 or more
points, and averaged to determine the average thickness.
[0103] When a periodically arranged lattice is not observed in the
silicon oxide layer by high-resolution electron microscopic
observation, it is confirmed that the silicon oxide has an
amorphous structure. The formation of the silicon oxide layer on
the fine metal particle surface can be confirmed, for instance, by
element analysis such as energy-dispersive X-ray fluorescence (EDX)
analysis, etc., or infrared spectroscopy. The TEM observation of
the fine composite metal particle and the EDX analysis of the
coating layer can confirm that the layer is composed of silicon
oxide. The infrared absorption spectrum of the fine composite metal
particles reveals that there is an absorption peak of silicon oxide
at a wave number of 1250 to 1020 cm.sup.-1, confirming the
formation of the silicon oxide layer.
[0104] The average particle size of ultrafine particles can be
determined, for instance, by dispersing an ultrafine particle
sample in a solvent, irradiating laser beams onto the sample to
measure a particle size distribution by diffraction. A measured
median diameter d50 is used as an average particle size. When the
particle size is as small as 100 nm or less, a sample is observed
by TEM or a scanning electron microscope (SEM) to take its electron
photomicrograph, in which the sizes of particles are measured in an
arbitrary area to obtain an average particle size. The average
particle size is determined from 50 or more of the measured
particles. When the fine particles have noncircular cross sections,
their maximum outer diameters and their minimum outer diameters are
averaged to obtain the average particle size.
[0105] When the silicon oxide layer is formed by the hydrolysis of
tetraethoxysilane, the thickness of the silicon oxide layer depends
on the amounts of tetraethoxysilane, water and a catalyst. The
excess amount of silicon oxide forms separate particles. The
thickness of the silicon oxide can be increased by adding an
electrolyte. Specific examples of the electrolyte are KCl, NaCl,
LiCl, NaOH, etc. With a controlled amount of the electrolyte, the
thickness of the silicon oxide can be adjusted in a range of 5 to
400 nm. The silicon oxide layer thicker than 400 nm decreases the
saturation magnetization of the fine composite metal particles. The
more preferred thickness of the silicon oxide layer is 5 to 100
nm.
[0106] An inorganic material outside the innermost layer may be a
gold layer in place of the silicon oxide layer. The gold layer may
further be formed on the silicon oxide layer. Fine colloidal gold
particles need only be applied to the coating layer, and the
resultant gold layer may be heat-treated. The first coating layer
may be plated with Ni, etc. and then with Au.
[5] Resin Layer
[0107] The multilayer inorganic coating may be covered with a
resin. The resin coating may be formed by the precipitation
polymerization of monomers such as monofunctional vinyl monomers.
The monofunctional vinyl monomers may contain polyfunctional vinyl
monomers in a range causing substantially no cross-linking, for
instance, less than 0.5 mol % of the total monomers. The resin
coating is particularly a polystyrene resin coating. The
resin-coated fine composite metal particles may be aggregated to
have a controlled secondary particle size. The above-described
silicon oxide layer may be formed on the resin coating.
[0108] An intermediate layer of a resin may be formed between the
innermost layer in contact with the metal core and the outer
inorganic layer. Specifically, the metal core may be coated with an
innermost layer of carbon and/or boron nitride, or at least one
element selected from the group consisting of Si, V, Ti, Al, Nb, Zr
and Cr, a resin layer, and then a silicon oxide layer. With the
resin coating, the particle size and specific gravity of the fine
composite metal particles can be controlled.
[0109] The outermost layer is preferably a silicon oxide layer, a
gold layer or a resin layer, though all the fine composite metal
particles need not be coated with such layers. In addition, each
fine particle is preferably completely coated, though all the fine
composite metal particles need not be coated. The coating ratio of
the particles is preferably 90% or more. The coating ratio is
calculated by (n/N).times.100 (%), wherein N is the total number of
particles, and n is the number of particles, 50% or more of whose
surfaces are coated with silicon oxide. When there are a small
percentage of particles coated with silicon oxide, the effect of
improving oxidation resistance and corrosion resistance is low.
Thus, the coating ratio by silicon oxide is more preferably 95% or
more. The fine composite metal particles of the present invention
having a multilayer coating of 2 or more different inorganic
materials have such good corrosion resistance that the degradation
of saturation magnetization is 10% or less in a corrosion
resistance test under the conditions of a temperature of
120.degree. C. and a humidity of 100% for 12 hours, exhibiting
stable properties as magnetic beads.
[6] Surface Modification
[0110] The silicon oxide layer may be treated with
amino-group-containing silane coupling agents to have functional
groups such as --NH.sub.2, etc. The silane coupling agents may be
specifically .gamma.-aminopropyltrialkoxysilane,
N-.beta.-(aminoethyl)-.gamma.-aminopropyltrialkoxysilane,
N-.beta.-(aminoethyl)-.gamma.-aminopropyl methyl dialkoxysilane,
N-phenyl-.gamma.-aminopropyltrialkoxysilane,
.gamma.-aminopropyltriethoxysilane, or
N-(.beta.-aminoethyl)-.gamma.-aminopropyltrimethoxysilane. With
functional groups such as --NH.sub.2, --OH, --COOH, etc. on the
surface of the silicon oxide layer, the fine composite metal
particles have an improved function of extracting
biosubstances.
[0111] The fine composite metal particles of the present invention,
particularly those having a silicon oxide layer and optionally a
surface-modifying layer of --NH.sub.2, --OH, --COOH, etc. outside
the inorganic layer, are chemically stable with high saturation
magnetization. Accordingly, they are suitable for the extraction of
biosubstances as so-called magnetic beads.
[0112] The present invention will be described in further detail
referring to EXAMPLES below without intention of restricting the
present invention thereto.
Example 1
[0113] 5 g of .alpha.-Fe.sub.2O.sub.3 powder (metal oxide powder)
having an average particle size of 0.03 .mu.m and 5 g of carbon
powder having an average particle size of 20 .mu.m were mixed for
10 minutes in a V-type mixer. The resultant mixed powder was
charged in a proper amount into a boron nitride crucible, and the
crucible was placed in a tubular furnace, in which the mixed powder
was heated from room temperature at a rate of 3.degree. C./min kept
at 1000.degree. C. for 2 hours, and then cooled to room temperature
at a rate of 3.degree. C./min. in a nitrogen gas stream at a flow
rate of 2 L/min With respect to each carbon powder before and after
the heat treatment, an X-ray diffraction measurement (Cu, K.alpha.
lines) was conducted to obtain diffraction patterns shown in FIG. 1
(before the heat treatment) and FIG. 2 (after the heat treatment).
(002) Peaks of graphite and (110) peaks of .alpha.-Fe were mainly
detected in the heat-treated powder. The magnetic properties of the
heat-treated powder were measured by a sample-vibrating
magnetometer (VSM). The results are shown in Table 1. The
saturation magnetization was about 100 times larger in Example 1
than in Comparative Example 1, and this result in combination with
the result of the X-ray diffraction measurement indicates that
Fe.sub.2O.sub.3 was reduced to Fe. After the heat-treated powder
was placed at 100% RH, 120.degree. C., and 1 atm for 24 hours in a
pressure cooker test machine, the oxygen content in the powder was
analyzed by an analyzer of oxygen, nitrogen and hydrogen in metals
(EMGA-1300 available from Horiba Ltd.). The analysis results of the
oxygen content are shown in Table 2. There was no increase in the
oxygen content after the pressure cooker test, indicating that Fe
powder was coated with a graphite layer. Incidentally, the above
analysis of oxygen, nitrogen and hydrogen in metals comprises
charging 0.5 g of a powder sample into a graphite crucible, rapidly
heating the crucible to 2000 to 3000.degree. C. to thermally
decompose the sample to generate a gas containing CO.sub.2, N.sub.2
and H.sub.2O, and detecting them by a chromatograph and a heat
conductivity detector to analyze the amounts of O, N and H.
Comparative Example 1
[0114] The mixed powder was heat-treated and subjected to an X-ray
diffraction measurement, a VSM measurement and a pressure cooker
test in the same manner as in Example 1 except for changing the
heat treatment temperature to 500.degree. C. There was no change in
an X-ray diffraction pattern before and after the heat treatment,
suggesting that no reaction occurred. The saturation magnetization
was not substantially changed either.
Comparative Example 2
[0115] Fe powder having an average particle size of 0.02 .mu.m
(ultrafine particles available from Vacuum Metallurgical Co., Ltd.)
was subjected to a corrosion resistance test under the same
conditions as in Example 1. The saturation magnetization was
reduced to 75.4.times.10.sup.-6 Wbm/kg, about 30% of the pure iron
level (about 260.times.10.sup.-6 Wbm/kg).
TABLE-US-00001 TABLE 1 Saturation Magnetization Coercivity No. (Wb
m/kg) (kA/m) Example 1 131 .times. 10.sup.-6 8.04 Comparative
Example 1 1.30 .times. 10.sup.-6 140 Comparative Example 2 75.4
.times. 10.sup.-6 135
TABLE-US-00002 TABLE 2 Amount of Oxygen (% by mass) Before
Corrosion After Corrosion No. Resistance Test Resistance Test
Example 1 0.11 0.11 Comparative Example 1 15.0 15.2 Comparative
Example 2 10.8 27.5
[0116] FIG. 3 is an electron photomicrograph showing the structure
of ultrafine metal particle of Example 1, which was observed by
TEM. In the TEM observation, no work likely to damage or change the
particles was carried out at all except for necessary adjustment of
the sample. FIG. 4 is a slightly enlarged schematic view for
explaining the structure in FIG. 3. Ultrafine metal particles 11
were .alpha.-Fe particles 12 each entirely coated with a thin
graphite layer 20. This coating layer 20 effectively prevents the
oxidation of each .alpha.-Fe particle 12. It is presumed that
projections 21, 21b on the thin graphite layer 20 are those grown
from the graphite layer or foreign matter attached to the graphite
layer. Bright and dark stripes 13a, 13b, 13c on the .alpha.-Fe
particles 11 are an interference pattern (shown by phantom lines)
due to the substantially spherical shape of the .alpha.-Fe
particles 11. Because boundaries 14 of the thin graphite layer are
slightly unclear on both ends of the .alpha.-Fe particles, they are
shown by dotted lines. This is because perfect focusing is
difficult on substantially spherical shapes, not suggesting that
the .alpha.-Fe particles 11 actually have obscure shapes. A region
encircled by a dashed line is a collodion layer 15 for fixing the
ultrafine metal particles 11 to a sample holder for TEM
observation. FIG. 4 indicates that three lines 16 are as long as 20
nm. A scale, on which the photograph of FIG. 3 was taken, is copied
to FIG. 4.
[0117] FIG. 5 is a TEM photomicrograph showing the structure of the
particle of the present invention, which shows a lower left portion
in FIG. 3 in an enlarged manner to scrutinize the structure of the
thin graphite layer 20. FIG. 6 is a schematic view for explaining
the structure of the particle shown in FIG. 5. A thin graphite
layer 20 is mainly constituted by graphite crystals. For instance,
lattice fringes 20a, 20b, 20c with substantially equal intervals
indicate laminar lattice planes of graphite, substantially in
parallel to the surface of the .alpha.-Fe particle 12.
[0118] Because the .alpha.-Fe particle is spherical and has slight
raggedness on its surface, some part of the thin graphite layer is
inclined to the surface of the .alpha.-Fe particle 12, like lattice
fringes 20f. The lattice fringes 20f generate other lattice fringes
20e and further lattice fringes 20d. Though not shown in the
figure, the lattice fringes 20d are substantially in parallel to
the surface of the .alpha.-Fe particle 12. As shown in FIGS. 5 and
6, the laminar lattice planes have varied orientations, and some of
them (satin portions) are obscure in their orientations in the thin
graphite layer. A substantially uniform thin graphite layer was
formed, such that crystals grow with adjacent crystals aligned and
with surfaces in parallel to the surface of the .alpha.-Fe particle
12.
[0119] FIG. 6 schematically indicates part of lattice fringes by
solid lines and dotted line in the thin graphite layer 20. Though
not shown in the figure, there are crystals even in blank portions.
It is presumed that there is an intermediate layer 25 between the
surface of the .alpha.-Fe particle 12 and the thin graphite layer
20, and its details are explained referring to FIGS. 7 and 8.
[0120] FIG. 7 is a TEM photomicrograph showing the structure of the
particle of the present invention, which shows the thin graphite
layer 20 in FIG. 5 in an enlarged manner. FIG. 8 is a slightly
enlarged schematic view showing the structure in FIG. 7. The
.alpha.-Fe particle 12 has lattice fringes 24 along the arrow a,
indicating crystal planes peculiar to .alpha.-Fe. The arrangement
of Fe atoms in row is shown by dotted lines. Though the lattice
fringes along the arrow a are disturbed near the surface of the
.alpha.-Fe particle 12, their ends constitute flat surfaces as
sites, from which graphite crystals gradually grow. This region is
called an intermediate layer 25. The thin graphite layer 20 grows
via the intermediate layer 25.
[0121] If the .alpha.-Fe particle 12 has a relatively smooth
spherical surface (flat surface) as shown in FIG. 8, the laminar
lattice planes 22 of graphite regularly grow in parallel along the
arrow d, resulting in a dense and extremely thin coating. The term
"dense" used herein means that the coating has portions in which
regular lattice planes are laminated. 15 to 17 laminar lattice
planes were laminated in a direction perpendicular to the arrow d
to constitute an extremely thin coating. It seems that the
intermediate layer 25 was as thick as 1 to 2 layers in the laminar
lattice planes 22 of graphite. When graphite crystal planes just
starting to grow are included in the intermediate layer, the
intermediate layer 25 is as thick as about 2 to 4 layers in the
laminar lattice planes 22 of graphite.
[0122] It is presumed that dislocations 23 are portions having
discontinuity in the crystal structure because of uneven crystal
growth. When growth in a portion delays by one layer due to lattice
defects and then resumes in the course of growth of laminar
lattices, it is likely that a lattice plane of the (n-1)-th layer
in the portion merges with a lattice plane of the n-th layer in an
adjacent portion into one plane (dislocated plane). When the
formation of dislocated planes is scarce, the resultant layer is a
uniform, dense, thin layer as a whole. Though there are projections
21b on the thin graphite layer 20, their clear photograph was not
taken. Accordingly, they are shown by dotted lines in FIG. 7.
Example 2
[0123] 5 g of .alpha.-Fe.sub.2O.sub.3 powder (metal oxide powder)
having an average particle size of 0.03 .mu.m and 5 g of carbon
powder having an average particle size of 20 .mu.m were mixed for
10 minutes in a V-type mixer. A proper amount of the resultant
mixed powder charged into a boron nitride crucible was heated from
room temperature at a rate of 3.degree. C./min. in a nitrogen gas
stream at a flow rate of 2 L/min. in a tubular furnace, kept at
1000.degree. C. for 2 hours, and cooled to room temperature at a
rate of 3.degree. C./min. in the furnace.
[0124] With respect to each carbon powder before and after the heat
treatment, an X-ray diffraction measurement (Cu, K.alpha. lines)
was conducted to obtain diffraction patterns shown in FIG. 9
(before the heat treatment) and FIG. 10 (after the heat treatment).
(002) Peaks of graphite and (110) peaks of .alpha.-Fe were mainly
detected in the heat-treated powder. In FIG. 10, white circles
denote peaks corresponding to the crystal structure of graphite,
black squares denote peaks corresponding to the crystal structure
of .alpha.-Fe, the axis of abscissas indicates a diffraction angle
2.theta.(.degree.), and the axis of ordinates indicates an X-ray
diffraction intensity (cps). A maximum-intensity peak of graphite
has a half-width of about 0.2.degree., indicating that the
heat-treated powder has good crystallinity. With respect to the
powder shown in FIGS. 9 and 10 (before and after the heat
treatment), the measurement of magnetic properties by VSM revealed
that the saturation magnetization was 1.30.times.10.sup.-6 Wbm/kg
before the heat treatment, and 131.times.10.sup.-6 Wbm/kg after the
heat treatment, indicating that Fe.sub.2O.sub.3 was reduced to
Fe.
[0125] The TEM observation of the heat-treated powder confirmed
tubular carbon micro-bodies as shown in FIG. 11. FIG. 11 is an
electron photomicrograph showing the structure of the particle of
the present invention. The composition analysis by EDX revealed
that black particles at ends of the carbon micro-bodies are Fe, and
that the tubes are C (carbon).
[0126] FIG. 12 is a schematic view corresponding to the particle
structure in the photograph of FIG. 11. A carbon micro-body 201 is
a carbon tube 203 grown from an Fe particle 202 in a curved manner.
There are pluralities of nodes 204 in the tube 203, regions
surrounded by opposing nodes and tube wall 203b constituting
cavities 205. A tip end 206 of the tube 203 is closed. The curved
carbon micro-body 201 appears to suggest that the thickness of the
tube wall and the interval of the nodes are not uniform. The tube
wall is thin particularly in portions 203c, 203e.
[0127] Another carbon micro-body 207 is a carbon tube 209 grown
from an Fe particle 208 in a curved manner and containing an Fe
particle 213 at a tip end. There are pluralities of nodes 210 in
the tube 209, regions surrounded by opposing nodes and the tube
wall constituting cavities 211. The Fe particle 220 near the Fe
particle 213 appear to be separated from each other by the tube
wall 220, etc. It is not clear whether the Fe particle 213 in the
carbon micro-body 207 was attached to the tube from the beginning
of growth or taken during the course of growth. Though the Fe
particle 208 and the tube wall 212 look overlapping the carbon
micro-body 201, they are not connected with each other. The other
Fe particle 214 exists alone. In the figure, straight or curved
dashed lines 215, 216 define the profiles of carbon particles.
Curved dashed lines 217, 218 define the profiles of collodion
layers for fixing the carbon micro-bodies, etc. onto a sample
holder of an electron microscope. The reference numeral 219 denotes
a scale in FIG. 12. Three lines for indicating the scale are as
long as 100 nm.
[0128] FIG. 13 is an electron photomicrograph showing the structure
of the particle of the present invention, which shows the junction
of the Fe particle 202 and the tube 203 in FIG. 11 in an enlarged
manner. FIG. 14 is a schematic view for explaining the structure
shown in the photograph of FIG. 13. For the simplification of
explanation, FIG. 14 indicates only main portions of the crystal
structure in FIG. 13 by solid lines and dotted lines. Accordingly,
blank portions around regions of dotted lines, if any, are only
omitted portions.
[0129] In FIG. 14, an Fe particle 202 has surfaces along particular
crystal planes in most regions, which are referred to as main Fe
phases 220, 221 below. A phase 225 with differently orientated
planes, a satin-surface phase 226, etc. were observed on the left
side of the main Fe phase 220. Though the main Fe phase 220, etc.
are depicted by parallel dotted lines, intervals of dots and lines
are not necessarily identical with those shown in FIG. 13.
[0130] Referring to FIG. 14, the tube 203 extends from a
hypothetical boundary 227 of the main Fe phase 221, and the inside
of the tube wall is partitioned by nodes 236, 239. A region
surrounded by the node 236, the Fe particle 202 and the tube wall,
and a region surrounded by the nodes 236, 239 and the tube wall
constituted cavities. The tube wall was mainly constituted by a
graphite phase.
Example 3
[0131] 73 g of .alpha.-Fe.sub.2O.sub.3 powder having an average
particle size of 0.03 .mu.m, 2.7 g of Ge powder having an average
particle size of 20 .mu.m, and 24.3 g of carbon black powder having
an average particle size of 0.02 .mu.m were mixed for 16 hours in a
ball-milling mixer. In the above formulation, Fe/Ge was 95/5 by
mass. A proper amount of the resultant mixed powder charged into an
alumina boat was heat-treated at 1000.degree. C. for 2 hours in a
nitrogen gas. After cooled to room temperature, a heat-treated
powder sample was recovered.
[0132] The X-ray diffraction pattern of the above powder sample is
shown in FIG. 15. Analysis by an analysis software "Jade, Ver. 5"
available from Rigaku Corporation revealed that a face-centered
cubic .gamma.-Fe (111) and a body-centered cubic .alpha.-Fe (110)
were identified in the diffraction pattern shown in FIG. 15. In the
graph of FIG. 15, the axis of abscissas indicates a diffraction
angle 2.theta.(.degree.), and the axis of ordinates indicates a
diffraction intensity I [arbitrary unit (a.u.)]. The diffraction
peak intensity ratio [I (111)/I (110)] is shown in Table 3. The
average particle size of .alpha.-Fe particles was 92 nm when
determined from the half-width. The magnetic properties of the
above powder sample were measured by VSM. The results are shown in
Table 3. The peak intensity ratio was much smaller than in
Comparative Example 3, suggesting that the sample had high
saturation magnetization.
Example 4
[0133] A powder sample was produced in the same manner as in
Example 3 except for replacing Ge with Al. The X-ray diffraction
pattern of the above powder sample is shown in FIG. 15. Analysis by
an analysis software "Jade, Ver. 5" available from Rigaku
Corporation identified a face-centered cubic .gamma.-Fe (111) and a
body-centered cubic .alpha.-Fe (110) in the diffraction pattern
shown in FIG. 15. The average particle size of .alpha.-Fe particles
determined from the diffraction peak intensity ratio and the
half-width is shown in Table 3. The magnetic properties of the
above powder sample measured by VSM are shown in Table 3. The peak
intensity ratio was smaller than in Comparative Example 3,
suggesting that the sample had high saturation magnetization.
Example 5
[0134] 73 g of .alpha.-Fe.sub.2O.sub.3 powder having an average
particle size of 0.03 .mu.m, 3.8 g of vanadium carbide (VC) powder
having an average particle size of 20 .mu.m, and 23.2 g of carbon
black powder having an average particle size of 0.02 .mu.m were
mixed, and the heat-treated powder sample was recovered in the same
manner as in Example 3. In the above formulation, Fe/V was 95/5 by
mass. The X-ray diffraction pattern of the above powder sample is
shown in FIG. 15. The diffraction peak intensity ratio and the
average particle size of .alpha.-Fe particles are shown in Table 3.
The magnetic properties of the above powder sample measured by VSM
are shown in Table 3. The peak intensity ratio was smaller than in
Comparative Example 3, suggesting that the sample had high
saturation magnetization.
Comparative Example 3
[0135] 75 g of .alpha.-Fe.sub.2O.sub.3 powder having an average
particle size of 0.03 .mu.m, and 25 g of carbon black powder having
an average particle size of 0.02 .mu.m were mixed without adding an
element X, and a heat-treated powder sample was recovered in the
same manner as in Example 3. The X-ray diffraction pattern of the
above powder sample is shown in FIG. 15. The intensity ratio [I
(111)/I (110)], the average particle size and the magnetic
properties measured in the same manner as in Example 1 are shown in
Table 3. The (111) peak intensity ratio was larger than in Examples
3 to 5, suggesting that the sample had low saturation
magnetization.
TABLE-US-00003 TABLE 3 Peak Saturation Particle Intensity Ratio
Magnetization Coercivity No. Size (nm) I(111)/I(110) (Am.sup.2/kg)
(kA/m) Example 3 92 0 164 0.9 Example 4 74 0.17 132 1.9 Example 5
86 0.12 152 1.7 Comparative 66 0.43 118 2.4 Example 3
Examples 6 to 9
[0136] .alpha.-Fe.sub.2O.sub.3 powder having an average particle
size of 0.03 .mu.m and CO.sub.3O.sub.4 powder having an average
particle size of 0.6 .mu.m at a ratio shown in Table 4, and carbon
black powder having an average particle size of 0.02 .mu.m in such
an amount that it was 30% by mass were dry-mixed for 16 hours in a
ball-milling mixer. The resultant mixed powder charged into an
alumina boat was heat-treated at 1000.degree. C. for 2 hours in a
nitrogen gas atmosphere having a purity of 99.9% or more with an
oxygen content in the atmosphere controlled to 10 ppm or less. The
average particle size of each powder was determined by measuring
the diameters of 60 fine particles arbitrarily selected in a TEM
photograph, and averaging them.
[0137] The above powder sample was subjected to an X-ray
diffraction measurement. Using RINT2500 available from Rigaku
Corporation, the measurement was carried out with .theta./2.theta.
scanning in a 2.theta. range of 40.degree. to 50.degree. to
determine the intensity of a (111) peak of a face-centered cubic
(fcc) crystal and a (110) peak of a body-centered cubic (bcc)
crystal. The X-ray diffraction pattern measured is shown in FIG.
16, in which the axis of abscissa indicates a diffraction angle
2.theta.(.degree.), and the axis of ordinates indicates a relative
intensity of the diffraction pattern. Because overlapping
diffraction patterns are not discernible, the patterns are depicted
with the scale of intensity displaced. The diffraction pattern was
analyzed by "Jade, Ver. 5," an analysis software available from
Rigaku Corporation. The diffraction peak intensity ratio [I (111)/I
(110)] and the average particle size determined from the half-width
of the (110) peak are shown in Table 5. The magnetic properties of
the above powder sample measured by VSM-5 (available from Toei
Industry Co., Ltd.) at a magnetic field in a range of .+-.2 T are
shown in Table 5.
Comparative Example 4
[0138] A powder sample was produced in the same manner as in
Example 6 to 9 except for using 70% by mass of
.alpha.-Fe.sub.2O.sub.3 powder having an average particle size of
0.03 .mu.m, and 30% by mass of carbon black powder having an
average particle size of 0.02 .mu.m. The X-ray diffraction pattern
of the sample is shown in FIG. 16, and the properties of the sample
are shown in Table 5.
Comparative Example 5
[0139] A powder sample was produced by the same materials (see
Table 4) and production method as in Examples 6 to 9, except for
using 70% by mass of CO.sub.3O.sub.4 powder having an average
particle size of 0.6 .mu.m, and 30% by mass of carbon black powder
having an average particle size of 0.02 .mu.m. The X-ray
diffraction pattern of the sample is shown in FIG. 16, and the
properties of the sample are shown in Table 5. The average particle
size of nano-sized particles constituting the sample was determined
from the (111) peak.
TABLE-US-00004 TABLE 4 Formulation (% by mass) No. Fe.sub.2O.sub.3
Co.sub.3O.sub.4 C Example 6 55 15 30 Example 7 50 20 30 Example 8
45 25 30 Example 9 40 30 30 Comparative 70 0 30 Example 4
Comparative 0 70 30 Example 5
TABLE-US-00005 TABLE 5 After Heat Treatment Average Saturation
Particle Magnet- Co/Fe I(111)/ size ization Coercivity No. (by
mass) I(110) (nm) (Am.sup.2/kg) (kA/m) Example 6 0.30 0.17 38 134
9.8 Example 7 0.44 0.12 31 139 11 Example 8 0.61 0.03 27 150 12
Example 9 0.82 0.09 23 141 12 Comparative 0 0.31 49 82.4 6.1
Example 4 Comparative .infin. -- 98 111 3.6 Example 5
[0140] It is clear from Table 5 that the ratio of I (111)/I (110)
in the samples of Examples 6 to 9 is as small as less than 0.2,
much smaller than in Comparative Examples 4 and 5, suggesting that
the addition of Co suppresses the precipitation of a .gamma. phase.
The samples of Examples 6 to 9 had as high saturation magnetization
as more than 120 Am.sup.2/kg, suggesting that the addition of Co
increased the volume ratio of an a phase having ferromagnetism,
resulting in improved saturation magnetization. Nano-sized
particles constituting the powder samples of Examples 6 to 9 had
smaller average particle sizes than those of Comparative Examples 4
and 5, indicating that fine particles having a body-centered cubic
crystal structure (.alpha. phase) were obtained.
Example 10
[0141] .alpha.-Fe.sub.2O.sub.3 powder having an average particle
size of 0.6 .mu.m and boron powder having an average particle size
of 30 .mu.m were mixed in equal amounts, and heat-treated at
1100.degree. C. for 2 hours in a nitrogen gas stream. Unnecessary
non-magnetic components were removed from the product to obtain
fine iron particles having an average particle size of 2 .mu.m each
coated with boron nitride. 5 g of this fine particles were
dispersed in 100 ml of ethanol, to which tetraethoxysilane was
added. While stirring this dispersion, a mixed solution of 22 g of
pure water and 4 g of ammonia water was added. Thereafter, the
resultant dispersion was stirred by a ball mill, while properly
adjusting the concentration of the tetraethoxysilane and the
stirring time by a ball mill. It was then dried at 100.degree. C.
or higher in the air, and further heat-treated at 400.degree. C. in
a nitrogen atmosphere.
[0142] The resultant fine iron particles was observed by TEM and
analyzed by EDX, confirming that each fine iron particle had a
multilayer coating comprising a boron nitride layer in contact with
the particle and then a silicon oxide layer outside the boron
nitride layer. The boron nitride layer was as thick as 4 nm. The
thickness of the silicon oxide layer was changed from 5 nm to 80
nm, by changing the ball-milling stirring time from 10 minutes to 3
hours. Also, when the amount of tetraethoxysilane added was changed
from 0.5 g to 2 g with a ball-milling stirring time fixed to 3
hours, the thickness of the resultant multilayer coating changed
from 5 to 80 nm. Lattice fringes assigned to a hexagonal crystal
structure were observed in the boron nitride layer. On the other
hand, no lattice fringes were observed in the silicon oxide layer,
suggesting that the silicon oxide layer had an amorphous structure.
The measurement of infrared absorption spectra revealed absorption
peaks of silicon oxide in a range of a wave number of 1250 to 1020
cm.sup.-1, confirming the formation of the silicon oxide layer.
[0143] To examine the effect of the silicon oxide layer to increase
electric resistance, fine particles having a 60-nm-thick silicon
oxide layer among those having a multilayer inorganic coating
obtained by the above method were pressed at 20 MPa or more to form
a flat plate. A mold was coated with a silver paste for an
electrode at both ends to measure electric resistivity between the
two electrode terminals. The relation between the thickness (nm)
and resistivity (.OMEGA.m) of the silicon oxide layer measured
above is shown in FIG. 17.
[0144] To examine the corrosion resistance of the above fine iron
particles having a composite coating of boron nitride and silicon
oxide, their magnetic properties were compared before and after the
corrosion resistance test, which was conducted at a temperature of
120.degree. C. and a humidity of 100% for 12 hours by a pressure
cooker test machine. The magnetic properties were measured by VSM.
Saturation magnetization obtained by the VSM measurement before and
after the corrosion resistance test, and a demagnetization ratio
obtained therefrom are shown in Table 6. The saturation
magnetization of the resultant fine composite iron particles before
and after the corrosion resistance test was 64% and 61%,
respectively, of that of iron.
TABLE-US-00006 TABLE 6 Saturation Magnetization (A m.sup.2/kg)
Demagnetization No. Before.sup.(1) After.sup.(2) Ratio (%) Example
10 140 134 4.3 Example 11 148 140 5.4 Example 12 152 143 5.9
Example 13 155 142 8.4 Example 15 160 152 6.9 Comparative 206 165
20.0 Example 6 Note: .sup.(1)Before the corrosion resistance test.
.sup.(2)After the corrosion resistance test.
Example 11
[0145] Iron oxide powder having an average particle size of 30 nm
and carbon powder having an average particle size of 20 .mu.m were
mixed in equal amounts, and heat-treated at 1000.degree. C. for 2
hours in a nitrogen gas atmosphere, to obtain fine, carbon-coated
iron particles having an average particle size of 1 .mu.m. The
particles were then coated with silicon oxide in the same manner as
in Example 10.
[0146] The resultant fine particles were observed by TEM and
analyzed by EDX to confirm that each fine iron particle had a
multilayer coating comprising an inner carbon layer in contact with
the iron particle and an outer silicon oxide layer. The carbon
layer was as thick as 10 nm on average, and the thickness of the
silicon oxide layer was ranging from 8 nm to 90 nm. Lattice fringes
assigned to a hexagonal crystal structure were observed in the
carbon layer, confirming that the carbon layer was based on a
graphite phase. On the other hand, lattice fringes were not
observed in the silicon oxide layer, indicating that the silicon
oxide layer had an amorphous structure. The saturation
magnetization of the fine composite iron particles was 68% of that
of iron. The electric resistivity of the fine magnetic particles
was measured in the same manner as in Example 10. The relation
between the thickness and electric resistivity of the silicon oxide
layer measured is shown in FIG. 17. Corrosion resistance was also
evaluated in the same manner as in Example 10. The results are
shown in Table 6.
[0147] One fine iron particle having a particularly small diameter
particle size among those obtained in Example 11 was observed by
TEM as shown in FIG. 18. FIG. 19 is a schematic view depicting an
important portion of the photograph of FIG. 18. The fine particle
had a multilayer coating comprising an inner carbon layer 2 in
contact with an iron core 1, and an outer silicon oxide layer 3.
This carbon layer 2 was as thick as about 5 nm, and the silicon
oxide layer 2 had a thickness ranging from 10 nm to 40 nm. Lattice
fringes assigned to a hexagonal crystal structure were observed in
the carbon layer, confirming that the carbon layer was based on a
graphite phase. On the other hand, lattice fringes were not
observed in the silicon oxide layer, indicating that it had an
amorphous structure. Surrounding smaller-diameter particles were a
silicon byproduct formed separately from the fine iron
particles.
[0148] FIG. 20 is a TEM photograph showing part of the particle in
FIG. 18 in an enlarged manner, and FIG. 21 is a schematic view
showing an important portion of the photograph of FIG. 20. It is
clear from FIG. 20 that the Fe core 1 was coated with a
uniform-thickness carbon layer 2.
Example 12
[0149] Fine, composite, magnetic particles each comprising a
magnetic iron-cobalt alloy core and a multilayer coating comprising
a carbon layer and 10-nm-thick silicon oxide layer were produced in
the same manner as in Example 11, except that iron oxide particles
and cobalt oxide particles having the same average particle size,
and carbon powder in an equal amount were mixed in the production
of carbon-coated, fine magnetic particles. The corrosion resistance
of the fine, composite, magnetic particles was evaluated in the
same manner as in Example 10. The results are shown in Table 6. The
saturation magnetization of the resultant fine composite particles
before and after the corrosion resistance test was 70% and 66%,
respectively, of that of iron.
Example 13
[0150] Fine magnetic particles were produced in the same manner as
in Example 11 except for using aluminum powder having an average
particle size of 2 .mu.m in place of carbon powder. Electron
microscopic observation and EDX analysis confirmed that each
resultant fine magnetic particle had a 3-nm-thick coating layer of
aluminum oxide. The fine magnetic particles were then coated with a
5-nm-thick silicon oxide layer in the same manner as in Examples.
The saturation magnetization of the resultant fine composite iron
particles was 71% of that of iron. The electric resistivity and
corrosion resistance of the fine magnetic particles measured in the
same manner as in Example 10 are shown in FIG. 17 and Table 6.
Example 14
[0151] Fine magnetic particles were produced in the same manner as
in Example 11 except for using titanium powder having an average
particle size of 2 .mu.m in place of carbon powder. Electron
microscopic observation and EDX analysis confirmed that the
resultant fine magnetic particles had a 5-nm-thick coating layer
composed of a titanium compound. The resultant fine magnetic
composite particles were then coated with a 50-nm-thick silicon
oxide layer in the same manner as in Example 11. The saturation
magnetization of the resultant fine composite iron particles was
65% of that of iron.
Example 15
[0152] Fine iron particles coated with a boron nitride layer and an
outermost 10-nm-thick silicon oxide layer were produced in the same
manner as in Example 10. The saturation magnetization of the
resultant fine composite iron particles was 73% of that of iron.
The fine composite iron particles were dispersed in substantially
neutral water, and mixed with colloidal gold having an average size
of 4 nm having a surface potential adjusted such that its electric
double layer potential G potential) on the surface was positive.
Because the surface potential of the fine iron particles was
negative in neutral water, each fine composite iron particle was
coated with colloidal gold particles by sufficient stirring. The
fine composite iron particles were filtered out, dried, and then
heat-treated at 700.degree. C. in a nitrogen gas atmosphere to
produce multilayer-coated fine composite iron particles having a
uniform coating layer of fine gold particles. The corrosion
resistance was evaluated in the same manner as in Example 10. The
results are shown in Table 6. The multilayer-coated iron particles
were suspended in a solution of a fluorescein-labeled rabbit
protein (immunoglobulin). After washing, the fluorescent intensity
by fluorescein was measured to calculate the amount (g) of
immunoglobulin coupled to the multilayer-coated iron particles. The
relation between the concentration (g/mol) of immunoglobulin in the
protein solution used and the amount of immunoglobulin coupled to
the multilayer-coated iron particles is shown in FIG. 22.
Example 16
[0153] A sample was produced in the same manner as in Example 11,
except that 0.03 g of KCl was added as an electrolyte in the
coating treatment of particles with silicon oxide. FIG. 23 is a TEM
photograph of the resultant fine composite iron particles. FIG. 24
is a schematic view showing an important portion of the photograph
of FIG. 23. The resultant multilayer-coated fine composite iron
particles had an inner carbon layer in contact with the Fe core 1,
and an outer silicon oxide layer 3. The TEM observation of the fine
particles revealed that the silicon oxide layer was as thick as 360
nm. The saturation magnetization of the fine composite iron
particles was 66% of that of iron.
Example 17
[0154] Fine iron particles each having a composite coating layer
comprising an inner carbon layer and an outermost 100-nm-thick
silicon oxide layer were produced in the same manner as in Example
11. The attachment of amino groups to the surfaces of the resultant
fine particles was confirmed by a fluorescent-labeling method using
a fluorescent substance (Rohodamine-x NHS) specifically coupling to
amino groups. The fine composite iron particles were dispersed and
stirred in a 0.5-% aqueous solution of
3-(2-aminoethylaminopropyl)trimethoxysilane for 3 hours so that
amino groups were carried by the surfaces of the fine composite
iron particles. The fine particles were then added to a solution of
Rohodamine-x NHS in N,N-dimethylformamide and stirred. FIG. 25 is a
photograph of the fine particle taken by a fluorescent inverted
microscope, and FIG. 26 is a schematic view for explaining the
photograph of FIG. 25. FIG. 26 shows fluorescence-emitting
particles. This indicates that --NH.sub.2 groups (Rohodamine-x NHS)
were carried by the surfaces of the fine composite metal
particles.
Example 18
[0155] Fine composite iron particles having a multilayer coating
comprising an inner carbon layer and an outermost 100-nm-thick
silicon oxide layer were produced in the same manner as in Example
11. To evaluate a DNA-extracting performance, a DNA extraction kit,
"Mag Extractor-Genome-.RTM." available from Toyobo Co., Ltd., was
used to carry out DNA extraction by the following procedures.
First, 25 mg of multilayer-coated fine composite particles were
dispersed in 100 .mu.L of a Tris-EDTA solution (pH 8.0), and 1
.mu.g of DNA (630 bp) was added to the resultant fine particles
dispersion. DNA was coupled to the multilayer-coated fine composite
particles in a dissolving/absorbing liquid attached to the DNA
extraction kit, and washed with a cleansing liquid attached to the
extraction kit and a 70-% aqueous ethanol solution. It was then
stirred in sterilized water to obtain a DNA-extracted aqueous
solution. In these steps, a magnetic stand available from Promega
was used to separate out the multilayer-coated fine composite
particles. The amount of extracted DNA was measured by an
electrophoresis method. The results are shown by lanes 1 and 2 in
FIG. 27. FIG. 28 is a schematic view for explaining the photograph
of FIG. 27. FIG. 28 shows a band 6 corresponding to extracted
nucleic acid. This result indicates that the multilayer-coated fine
composite particles of present invention having an outermost
silicon oxide layer can extract DNA. 0.70 .mu.g of DNA was
extracted among 1 .mu.g of DNA introduced, indicating that magnetic
beads comprising the multilayer-coated fine composite particles of
the present invention have an excellent function of extracting
nucleic acid.
Example 19
[0156] Fine iron particles coated with carbon and silicon oxide and
having amino groups carried on the outermost layer were produced in
the same manner as in Example 17. DNA extraction and
electrophoresis were carried out using these fine particles in the
same manner as in Example 18. The results are shown by lanes 3 and
4 in FIG. 27. The electrophoresis experimental results indicate
that DNA was extracted. 0.77 .mu.g of DNA was extracted among 1
.mu.g of DNA introduced, 10% higher than in Example 18, indicating
that the DNA-extracting performance is improved by having the fine
composite particles having a carbon layer and an outermost silicon
oxide layer carry amino groups.
Comparative Example 6
[0157] A silicon oxide coating layer was formed on the fine iron
particles using carbonyl iron particles having an average particle
size of 3 .mu.m to evaluate electric resistivity and corrosion
resistance in the same manner as in Example 10. The results are
shown in FIG. 17 and Table 6. Though the silicon oxide-coated, fine
carbonyl iron particles obtained in Comparative Example 6 exhibited
high saturation magnetization, they had a demagnetization ratio of
20% in the corrosion resistance test, extremely higher than those
of the multilayer-coated, magnetic, fine composite metal particles
of Examples 10 to 13 and 15. This indicates that the multilayer
coating of the fine composite metal particles with carbon and/or
boron nitride and silicon oxide extremely improves their corrosion
resistance. The fine particles obtained in Comparative Example 6
had lower resistivity than those of the multilayer-coated,
magnetic, fine composite metal particles of Examples 10 to 13 and
15. This appears to be due to the fact that the multilayer coating
of carbon and/or boron nitride and silicon oxide on the fine
composite metal particles provides high resistivity.
Comparative Example 7
[0158] A sample was produced in the same manner as in Example 11
except for using 5 g of tetraethoxysilane, 22 g of ammonia water
and 4 g of water. The silicon oxide layer had a thickness of 600
nm, and a saturation magnetization of 100 Am.sup.2/kg, 46% of that
of iron. This indicates that when the silicon oxide layer is as
thick as 600 nm, the saturation magnetization decreases. This
sample had large amounts of excessive silica spheres that did not
form the coating layer.
Comparative Example 8
[0159] Magnetite (Fe.sub.3O.sub.4) particles having an average
particle size of 30 nm used as fine magnetic particles were coated
with gold in the same manner as in Example 15, to measure the
amount of coupled immunoglobulin of a fluorescein-labeled rabbit.
The results are shown in FIG. 4.
Reference Example 1
[0160] A sample was produced to measure electric resistance in the
same manner as in Example 11, except for using 6.4 mol/kg (6.7 g)
of tetraethoxysilane, 25.7 mol/kg (4.5 g) of ammonia water, and
79.3 mol/kg (7.1 g) of water per a unit amount of metal particles.
The results are shown in FIG. 17. Though the silicon oxide layer
had a thickness of 70 nm and high resistivity, large amounts of
silicon oxide particles were formed immediately after the
production of the sample.
[0161] It is clear from FIG. 17 that the fine particles of the
present invention having a multilayer coating comprising a first
layer of boron nitride, carbon or aluminum oxide, etc. in contact
with the magnetic metal core and a second layer of silicon oxide
exposed outside have higher resistance than conventional ones. It
is also clear that in the formation of the silicon oxide layer, the
thickness and thus electric resistance of the oxide layer can be
controlled by properly adjusting the amount of tetraethoxysilane
added. Further, as is clear from Table 6, the fine particles of the
present invention having multilayer coatings of carbon, boron
nitride or aluminum oxide, and silicon oxide have sufficient
stability in oxidation resistance, etc.
[0162] In the present invention, the outermost surface layer may be
formed by a material such as gold, etc. suitable for attaching to
biosubstances. As shown in FIG. 22, because the particle cores are
composed of magnetic metals having high magnetic flux densities,
the fine particles of the present invention are highly suitable for
the separation and purification of biosubstances.
[0163] As described above, the fine composite metal particles of
the present invention are insulating and bioactive, as well as
having high saturation magnetization. For instance, the fine
composite metal particles of the present invention each comprising
a magnetic metal core having an average particle size of 10 .mu.m
or less, and a multilayer coating comprising 2 or more layers of
different inorganic materials have high insulation with reduced
deterioration of saturation magnetization. The fine composite metal
particles of the present invention can be produced at high
productivity.
[0164] The fine composite metal particles of the present invention
can be used for magnetic recording media such as magnetic tapes,
magnetic recording disks, etc., magnetic shields, electronic
devices such as parts for absorbing unnecessary electromagnetic
waves, filters for absorbing particular bandwidths, inductors,
yokes, etc., magnetic beads for extracting and separating DNA,
protein components, cells, etc.
* * * * *